Gravity casting mold trial-test adopts simplified but standardized verification flow, tailored for thick-wall aluminum castings with low precision requirements and high production volume.
The standard gravity mold trial-test consists of 4 independent pouring batches, one batch more than LPDC molds to verify natural flow filling balance.
Qualified trial products allow maximum porosity shrinkage of 1.2%, complying with industrial thick-wall casting tolerance standards without affecting structural strength.
Filling velocity balance is the core test index, requiring molten aluminum flow deviation controlled within 15% across all mold cavities.
Exhaust system test verifies 20% larger exhaust area design, ensuring no gas trapping defects during high-volume natural filling.
Cooling system inspection focuses on slow and uniform heat dissipation, matching 15–22mm channel spacing for thick-wall solidification.
Procast CAE simulation results for gravity molds prioritize flow field balance, with allowable simulation error within 6% of actual trial data.
H13 steel mold surface inspection after 400 trial cycles requires no obvious oxidation spots or sticky mold residues for formal delivery.
Thick-spoke aluminum wheel mold and conventional mechanical aluminum parts mold adopt this complete gravity trial-test specification.
Different from LPDC and CPC molds, gravity casting trial-test omits high-pressure sealing detection and focuses entirely on filling and solidification stability.
Trial-test dimensional tolerance standard is ±0.05mm, looser than high-pressure molds but sufficient for thick-wall casting assembly demands.
Gravity casting mold trial-test is designed to match the low-cost, high-efficiency positioning of thick-wall aluminum casting production. Since gravity molds rely entirely on natural gravity filling without auxiliary pressure, the trial-test core is to verify gating system rationality and flow uniformity, rather than pressure stability. Four batches of repeated pouring effectively eliminate unbalanced filling and local shrinkage defects caused by unreasonable runner design. The relatively loose porosity standard fully adapts to the structural characteristics of thick-wall castings, avoiding excessive inspection standards that increase production costs. Professional Procast CAE simulation optimizes flow velocity distribution in advance, ensuring consistent filling speed of each cavity. Long-cycle trial operation verifies the thermal stability of H13 hot-work steel under low-pressure working conditions. This standardized trial flow maximizes the cost-performance advantage of gravity casting molds, ensuring stable mass production of conventional aluminum castings while controlling mold manufacturing and testing costs within a reasonable range.
FAQs
Q1: How many trial batches do standard gravity molds require? A1: 4 independent pouring batches, one more than conventional LPDC molds.
Q2: What is the maximum allowable porosity for gravity trial castings? A2: Porosity shrinkage controlled within 1.2% for thick-wall product standards.
Q3: What is the core test index for gravity mold trial? A3: Molten aluminum filling velocity balance with 15% maximum deviation.
Q4: What is the allowable CAE simulation error for gravity molds? A4: Simulation data error controlled within 6% of actual production data.
Q5: What dimensional tolerance is qualified for gravity mold trial? A5: Loose standard ±0.05mm for thick-wall casting assembly.
Q6: Does gravity trial-test include pressure sealing inspection? A6: No, pressure detection is exclusive to LPDC and CPC high-pressure molds.
Q7: What products apply gravity mold trial standards? A7: Thick-spoke wheels and conventional mechanical aluminum casting parts.
